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Thermal Analysis

Thermal Analysis Artificial Intelligence Analysis FEA|CFD & AI Integration

The effects of heat and thermal management of structures is more and more critical as performance limits are pushed further by the need to have lighter, smaller and more efficient designs. Convection, radiation and conduction loads are obvious, but the need to include the effect of power losses and thermal energy from friction and external sources such as pipe flows means that analysts need to have more tools at their disposal to simulate thermal models accurately.
To accurately simulate thermal models and manage heat effectively, analysts must have access to a range of tools and techniques. These may include computational fluid dynamics (CFD) simulations, finite element analysis (FEA), and other modeling and simulation tools.

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Thermal Analysis, Integrated FEA|CFD with Artificial Intelligence

Electronic Systems Cooling & Heating

In the design phase of electronic devices, CFD and FEA based heat transfer software can be used to analyze the cooling capacity of components such as electronic chips and power systems. This helps to ensure that the components do not overheat, which can cause damage or degrade their performance.

CFD simulations can be used to model the flow of air or other fluids over the surface of the component, which can help to identify areas where heat is accumulating and determine the effectiveness of different cooling strategies. FEA simulations can be used to model heat transfer through materials, such as the thermal conductivity of a heat sink or the thermal resistance of a thermal interface material.

Heat pipes are also commonly used in electronic devices to transfer heat away from components and dissipate it into the surrounding environment. The design of heat pipes can be modeled using CFD and FEA simulations to optimize their cooling performance and ensure that they meet the thermal requirements of the device.

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Simulation Dynamics
Electronic Systems Cooling & Heating, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Electronic Systems Cooling & Heating

Heat Exchangers

Heat exchangers are involved in a variety of application areas, such as water treatment, resource refinery, nuclear power, food and beverage production, refrigeration, and more.

Heat exchanger analysis involves the transfer of heat between fluids and solids, where the fluids carry energy over large distances and the solids separate the fluids so that they can exchange energy without mixing. Heat exchangers are used in a wide range of application areas, such as water treatment, resource refinery, nuclear power, food and beverage production, refrigeration, and more.

In a heat exchanger, two fluids are separated by a solid surface, which can be in the form of tubes, plates, or fins. One fluid flows through the tubes or passages, while the other flows around the tubes or passages. Heat is transferred from the hot fluid to the cold fluid through the solid surface, resulting in a temperature difference between the two fluids.

The performance of a heat exchanger can be analyzed using a variety of methods, including CFD simulations, FEA simulations, and empirical correlations. CFD simulations can be used to model the flow of fluids through the heat exchanger and predict the heat transfer coefficient, while FEA simulations can be used to model the temperature distribution in the solid surface and predict the thermal stresses and deformations.

Empirical correlations, such as the Nusselt number and the Reynolds number, can be used to estimate the heat transfer coefficient and pressure drop in the heat exchanger based on experimental data. These correlations are useful for preliminary design and optimization of heat exchangers, but may not be accurate for all flow regimes and geometries.

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Simulation Dynamics
Heat Exchangers, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Heat Exchangers

Heat Transfer Simulations for Turbomachinery Systems

Most machines, especially those that operate under high-heat conditions such as turbines, boilers, and combustors, require strict control of thermal stresses and expansions. These machines are subject to thermal cycling, which can cause differential expansion and contraction between components and lead to premature failure if not properly controlled.

To control thermal stresses and expansions, engineers use CFD and FEA tools to calculate parameters of heat transfer between components. CFD tools such as OpenFoam, Ansys Fluent, and Siemens Star-ccm+ can be used to simulate the flow of fluids and gases within machines, while FEA tools such as Abaqus, Nastran, and LS-DYNA can be used to simulate the response of materials to thermal stresses and deformations.

By using these tools, our engineers can optimize the design of machines for thermal performance, identify potential hot spots and areas of stress concentration, and determine the best cooling strategies to reduce thermal stresses and expansions. These simulations can also help to reduce the time and cost associated with physical testing, as well as minimize the risk of failure during operation.

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Heat Transfer Simulations for Turbomachinery Systems, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Heat Transfer Simulations for Turbomachinery Systems

Passenger Thermal Comfort

The thermal and acoustic comfort of passengers is a critical design criterion for the air-conditioning and customization of a cabin. Engineers must ensure that the cabin provides a comfortable environment for passengers, which includes maintaining appropriate temperatures, humidity levels, and noise levels.

To achieve this, engineers typically conduct costly and time-consuming test series with specifically built cabin mock-ups to obtain information about the expected passengers' sensation of comfort in the design process. These tests can include measurements of temperature, humidity, and noise levels, as well as subjective evaluations of passenger comfort.

However, to reduce the time and cost associated with physical testing, our engineers use simulation tools such as CFD and FEA to analyze the performance of HVAC components, fans, blowers, and air channels in the cabin. These simulations can provide information on airflow patterns, temperature distribution, and noise levels, allowing engineers to optimize the design of the air-conditioning system and cabin layout for maximum thermal and acoustic comfort.

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Passenger Thermal Comfort, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Passenger Thermal Comfort

Stress Relief Heat Treatment

Stress relieving is a heat treatment process that reduces residual stresses in an assembly after welding. This process is important because residual stresses can cause distortion, cracking, and premature failure of the welded structure.

The stress relief heat treatment involves heating the welded assembly to a specific temperature, holding it at that temperature for a specified amount of time, and then cooling it down gradually. The time-temperature curves for heating, holding, and cooling phases are defined based on the material properties and the desired level of stress relief.

In FEA stress relief modeling, two mechanisms are taken into account: stress relaxation and time-dependent creep properties of the material. Stress relaxation occurs due to the decreased yield stress of the material during heating, while time-dependent creep properties refer to the tendency of materials to deform under constant stress over time.

By using FEA stress relief modeling, our engineers can predict the level of stress relief in a welded structure, optimize the stress relief heat treatment process, and identify potential areas of stress concentration that may require further analysis or modification.

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Stress Relief Heat Treatment, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Stress Relief Heat Treatment

Thermal Management in Buildings: HVAC/Climate Control

Thermal management is crucial in the design of buildings, as it affects the comfort of occupants and the energy efficiency of the building. Building designers need to consider heat and moisture variations in building components to ensure that the building performs optimally in terms of energy consumption and occupant comfort.

Heat transfer analysis is an important tool used by engineers to analyze thermal management in building components such as wooden frames, window frames, and porous building materials. By simulating heat transfer in these components, engineers can optimize the design of the building to ensure that heat is effectively transferred in and out of the building and that the building remains thermally stable.

In addition to heat transfer, Simulation Dynamics engineering team also analyzes water condensation and evaporation on building surfaces, heat and moisture storage, latent heat effects, as well as diffusion and convective transport of moisture. These factors can affect the durability and performance of building components, as well as the comfort of occupants.

By using advanced thermal management analysis techniques, engineers can optimize the design of buildings to ensure that they are energy efficient, thermally stable, and comfortable for occupants. This can help to reduce energy consumption, improve occupant comfort, and increase the overall lifespan of the building.

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Thermal Management in Buildings: HVAC/Climate Control, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Thermal Management in Buildings: HVAC/Climate Control

Thermal Stress Simulation

Thermal expansion is a common phenomenon that can lead to high levels of thermal stress, which can have both positive and negative effects on the performance of components and structures. In some cases, thermal expansion can be beneficial, such as in shrink fit and bimetallic temperature sensor applications, where thermal stress can be used to improve the fit and accuracy of the components. However, in other cases, thermal stress can be detrimental to the performance and lifespan of components and structures, leading to deformation, cracking, or failure.

To optimize the effect of thermal expansion and minimize the risk of thermal stress-induced failure, it is essential to have a good thermal design that accounts for the thermal properties and behavior of the materials used in the components or structures.

By using advanced thermal design techniques and multiphysics coupling methods with CFD and FEA, our engineers can optimize the design of components and structures to minimize the effect of thermal expansion and reduce the risk of thermal stress-induced failure.

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Thermal Stress Simulation, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Thermal Stress Simulation

Vehicle Thermal Management Simulation

Extending from steady-state to transient simulation is essential in investigating the real conditions of vehicle driving cycles. This enables engineers to accurately simulate the thermal behavior of vehicle components and systems under real-world operating conditions, including dynamic changes in temperature, pressure, and airflow.

At Simulation Dynamics, we use advanced simulation processes that are efficient and accurate in modeling real-world transient conditions. Our team of experienced engineers utilize a combination of finite element analysis (FEA) and computational fluid dynamics (CFD) solvers, including Abaqus, Ansys, LS-Dyna, Nastran, Siemens Star-ccm+, and Ansys Fluent, to perform detailed thermal analysis of vehicle components and systems.

By coupling FEA solvers with CFD solvers, we can simulate the thermal behavior of vehicle components and systems, including heat transfer, fluid flow, and heat exchange, under realistic operating conditions. This allows us to accurately model the performance and behavior of the components and systems, optimize their design, and ensure their durability and reliability under real-world conditions.

Cognitive FEA: Machine Learning-Predictive Structural Integrity

Simulation Dynamics
Vehicle Thermal Management Simulation, Ansys, Simulia, Siemens, Integrated FEA|CFD with Artificial Intelligence
Thermal Analysis: Vehicle Thermal Management Simulation